Fiber-based electric device

ABSTRACT

A method of manufacturing a fiber-based electric apparatus includes providing an elongate, flexible fiber core and layering an electric device on the fiber core.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/253,310, filed Oct. 17, 2008, which claims the benefit ofU.S. Provisional Patent Application No. 60/999,527, filed Oct. 18, 2007.The entire disclosures of these applications are incorporated herein byreference.

GOVERNMENT RIGHTS

This invention was made with government support under Contract No. AFOSR#FA9550-06-1-0399 awarded by the Air Force Office of ScientificResearch. The government has certain rights in the invention.

FIELD

The present disclosure relates to an electric device, and moreparticularly to a fiber-based electric device.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Electric devices such as photovoltaic devices, thermoelectric devices,light emitting devices and the like have been developed for varioususes. Typically, these devices are planar in shape and are relativelybulky, heavy, and rigid, which limits the usefulness of these devices.For instance, it can be difficult to incorporate these devices wherespace is limited, on non-planar base surfaces, and the like. Also,manufacturing an electronic device to make it smaller, lighter, and/ornon-planar can be prohibitively expensive and may detrimentally effectthe operating life of the device.

SUMMARY

A method of manufacturing a fiber-based electric apparatus is disclosed.The method includes providing an elongate, flexible fiber core andlayering an electric device on the fiber core.

Also, a method of manufacturing an electric apparatus is disclosed. Themethod includes providing a plurality of fiber-based electricapparatuses, each including an elongate flexible fiber core and at leastone electric device layered thereon. At least one of the plurality offiber-based electric apparatuses includes a plurality of first films andsecond films. The first and second films are alternatingly arrangedalong the axis of the respective fiber core. The first films abutcorresponding ones of the second films such that a plurality ofjunctions are defined between corresponding pairs of the first andsecond films. The method also includes operably securing the pluralityof fiber-based electric apparatuses together into a mat that defines afirst side and a second side such that a location of the plurality ofjunctions alternates in succession between the first side and the secondside along the axis of the respective fiber core.

Moreover, a method of manufacturing an electric apparatus is disclosed.The method includes providing a plurality of fiber-based electricapparatuses, each including an elongate, flexible fiber core and atleast one electric device layered thereon. The plurality of fiber-basedelectric apparatuses include a first fiber-based electric apparatus anda second fiber-based electric apparatus. The first fiber-based electricapparatus includes only one of a p-type material and an n-type material,and the second fiber-based electric apparatus includes only the other ofthe p-type material and the n-type material. The method further includesoperably securing the plurality of fiber-based electric apparatusestogether and electrically connecting the first and second fiber-basedelectric apparatuses together in parallel with at least one conductivemember.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1A is a perspective sectional view of a fiber-based electricapparatus according to the teachings of the present disclosure;

FIG. 1B is a cross sectional view of a fiber-based electric apparatus;

FIG. 2 is a cross sectional view of a fiber-based electric apparatus;

FIG. 3 is a schematic view of a fiber-based electric device of FIGS.1A-2;

FIG. 4 is a schematic view of the operation of the fiber-based electricdevice of FIGS. 1A-2;

FIG. 5 is a graph of operative characteristics of the fiber-basedelectric device of FIGS. 1A-2;

FIG. 6 is a perspective view of a woven mat that includes fiber-basedphotovoltaic apparatuses according to the present disclosure;

FIG. 7 is a graph comparing operative characteristics of planar-typephotovoltaic devices versus the fiber-based photovoltaic devicesaccording to the present disclosure;

FIG. 8A is a perspective sectional view of an exemplary embodiment of afiber-based OLED electric apparatus according to the present disclosure;

FIG. 8B is a top view of the fiber-based OLED of FIG. 8A in operation;

FIGS. 9A-9D are graphs illustrating various OLEDs including thefiber-based OLED of FIGS. 8A-8B;

FIG. 10 is a graph illustrating various OLEDs including the fiber-basedOLED of FIGS. 8A-8B;

FIG. 11 is a perspective sectional view of an exemplary embodiment of afiber-based thermoelectric apparatus according to the presentdisclosure;

FIG. 12 is a side view of the fiber-based thermoelectric apparatus ofFIG. 11;

FIG. 13 is a schematic view of the fiber-based thermoelectric apparatusof FIG. 11;

FIG. 14A is a sectional view of a woven mat that includes thefiber-based thermoelectric apparatus of FIG. 11;

FIG. 14B is a top view of the woven mat of FIG. 14A;

FIG. 15 is a graph illustrating the operating characteristics of thefiber-based thermoelectric apparatus of FIG. 11;

FIG. 16 is a schematic view of another embodiment of a woven mat thatincludes fiber-based thermoelectric apparatuses of the presentdisclosure;

FIG. 17 is a top view of the woven mat of FIG. 16;

FIG. 18 is a schematic view of the woven mat of FIG. 16;

FIG. 19 is a graph illustrating the operating characteristics of thethermoelectric apparatus of the present disclosure;

FIG. 20 is a graph illustrating the operating characteristics of thethermoelectric apparatus;

FIG. 21 is a schematic view of a manufacturing method for a fiber-basedelectric apparatus;

FIG. 22 is a schematic view of a manufacturing method for a fiber-basedelectric apparatus;

FIG. 23A is a schematic view of a machine for manufacturing afiber-based electric apparatus; and

FIG. 23B is a schematic view of another machine for manufacturing afiber-based electric apparatus.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

Referring now to FIGS. 1A, 1B and 2, one embodiment of a fiber-basedelectric apparatus is generally indicated at 10. Generally, thefiber-based electric apparatus 10 includes a flexible, fiber core 12 andan electric device, generally indicated at 15, that is layered on andsupported by the fiber core 12. In some embodiments, the electric device15 includes a plurality of layers as will be discussed. The electricdevice 15 can be flexible. As will be discussed, the fiber-basedelectric apparatus 10 can be relatively small, compact, and flexible andcan be configured in a variety of ways for a wide variety of uses.

In the embodiments discussed in relation to FIGS. 1A, 1B, and 2, theelectric device 15 functions as a photovoltaic (PV) device so as toconvert light into electricity. However, as will be discussed, theelectric device 15 can have various other functions without departingfrom the scope of the present disclosure.

In this embodiment, the fiber-based electric apparatus 10 is aphotovoltaic (PV) device and is operable for converting light intoelectricity; however, the apparatus 10 could be of any other suitabletype as will be discussed. As shown, the apparatus 10 includes anelongate, flexible fiber core 12.

In one embodiment, the core 12 is made out of aluminum oraluminum-coated fiber. However, the core 12 could be made out of anysuitable material. In the embodiments of FIGS. 1A-2, the electric device15 functions independent of the fiber core 12. Thus, the core 12provides structural support for the device 15, and the device 15operates substantially independently. In other embodiments, the electricdevice 15 functions in combination with the fiber core 12. For instance,the core 12 can be an electric conductor for the electric device 15 inaddition to providing structural support.

In the embodiments of FIGS. 1A-2, the electric device 15 includes aplurality of layers. More specifically, the device 15 includes an anode14 layered on the core 12. In one embodiment, the anode 14 includes aconductive polymer. Next, an organic layer 16 (i.e., an organic bulkheterojunction) is layered on the anode 14. In one embodiment, theorganic layer 16 includes at least one organic material. Also, a cathode18 is layered on the organic layer 16. In one embodiment, the cathode 18includes a conductive polymer. The cathode 18 can also haveanti-reflection properties to thereby control optical interferenceinside the organic layer 16.

Additionally, in some embodiments, the device 15 includes an auxiliaryconducting wire 20. The conducting wire 20 is helically wound on theoutside of the cathode 18 at a relatively low duty cycle. The conductingwire 20 is in electric contact with the cathode 18 and acts as a busline to facilitate transmission of electricity along the cathode 18. Inother embodiments, the wire 20 extends substantially parallel to theaxis of the core 12 instead of being wound helically about the device15.

Furthermore, in some embodiments, the fiber-based electric apparatus 10includes an encapsulating layer 22 (shown in phantom in FIG. 1A). Theencapsulating layer 22 is included over the cathode 18 and theconducting wire 20 for protection against abrasion and environmentalresistance. In some embodiments, the encapsulating layer 22 issubstantially transparent.

As shown in FIG. 2, the organic layer 16 (i.e., the active layers) andthe electrodes (i.e., the anode 14 and the cathode 18) are coaxiallyaligned on the core 12. In the embodiment shown, the core 12 has adiameter d, and the anode 14 is a metallic layer of a thickness t (FIG.2). Also, the organic layer 16 is a thin (e.g., approximately 1-200 nm)coating of photoactive organic material. Furthermore, the cathode 18 isa conducting polymer. The auxiliary conducting wire 20 has a thicknessd_(au), and is helically wound around the other layers at a relativelylow duty cycle. The encapsulating layer 22 is included to give theentire apparatus 10 a thickness of D.

FIG. 1B is a cross sectional view of an exemplary embodiment of theapparatus 10. It will be appreciated that the materials and thethickness dimensions discussed in relation to this embodiment are merelyexemplary and non-limiting, and the apparatus 10 can include anysuitable materials with any suitable dimensions without departing fromthe scope of the present disclosure. In this embodiment, the anode 14includes individual layers of polyimide, magnesium, and gold layered onthe core 12 at a total thickness of approximately 13 nm. Next, theorganic layer 16 includes individual layers of CuPc, C60, and Alq₃layered on the anode 14 at a total thickness of approximately 73 nm.Finally, the cathode 18 includes individual layers of MgAg and silverlayered on the organic layer 16 at a total thickness of approximately 11nm.

FIGS. 3 and 4 schematically illustrate the operation of the device 15 toconvert light into electricity. In the embodiment shown, the layers ofthe electric device 15 is represented with planar layers in FIGS. 3 and4; however, it will be appreciated that the layers shown in FIGS. 3 and4 represent the non-planar layers of the device 15 of FIGS. 1A-2. Whenlight is exposed to the device 15, light absorption, exciton diffusion,exciton dissociation, and charge conduction occurs as is known in otherprior art PV devices. As such, the light can be converted intoelectricity, and this electricity can be stored and/or be transferred toany other suitable load.

Moreover, FIG. 5 is a representative plot of the typical current-voltage(I-V) behavior of the PV device 15, wherein FF represents fill factor,V_(OC) represents open-circuit voltage, and I_(SC) representsshort-circuit current. Furthermore, FIG. 7 illustrates current density,j, versus voltage produced by the device 15 along with the conversionefficiency compared to conventional planar PV devices with and withoutindium tin oxide (ITO). In FIG. 7, line 19 represents operation in thedark, and line 17 represents operation under AM1.5 illumination.

It will be appreciated that the fiber-based electric apparatus 10 hasimproved mechanical flexibility, low weight, and thin layer structure ascompared to conventional photovoltaic devices. Also, manufacturing ofthe apparatus 10 is facilitated, because each layer can be deposited ona non-planar and non-crystalline substrate as will be discussed.Furthermore, the apparatus 10 can be formed on a mechanically strongfiber core 12, allowing energy harvesting functionality to be integratedwith load-bearing capability.

In addition, as shown in FIG. 6, a plurality of the fiber-based electricapparatuses 10 can be woven with other fibers 11 into a larger woven mat13. Electric leads (not shown) can be electrically coupled to therespective fiber-based electric apparatuses 10 for transfer of thegenerated electricity. Accordingly, the mat 13 can be used to convertlight into electricity. This can enable dramatically improvedfabrication procedures for multifunctional structures and, in view ofthe high specific power density, provide added functionality without asignificant weight penalty. Thus, the mat 13 can be directly integratedinto existing materials and existing objects, such as vehicle bodies,etc. for harvesting energy. Accordingly, the capabilities of thesematerials and objects can be augmented without sacrificing desiredproperties such as strength or flexibility or causing detrimentaleffects, such as a significant addition of weight.

Now referring to FIGS. 8A and 8B, another embodiment of a fiber-basedelectric apparatus is generally indicated at 110. In this embodiment,the fiber-based electric apparatus 110 is a light emitting diode (LED)device that converts electricity into light. More specifically, theelectric device is an organic LED device (i.e., an OLED device).

In the embodiment shown, the fiber-based electric apparatus 110 includesa core 112. Also, an anode 114 is layered on the core 112, an organiclayer 116 is layered on the anode 114, and a cathode 118 is layered onthe organic layer 116. Furthermore, in some embodiments, a conductorlayer 127 is layered on the core 112 between the core 112 and the anode114 for conducting electricity along the anode 114. In some embodiments,the anode 114 and/or the cathode 118 can include a plurality of layerswith sufficient material to provide long-range conduction at relativelylow resistive loss, and with a suitably treated surface to facilitatecharge injection to or collection from the surrounding active layers.

FIG. 8A illustrates one embodiment of the materials and dimensions ofthe core 112, anode 114, organic layer 116, and cathode 118. However, itwill be appreciated that these components can be of any suitable typeand dimension without departing from the scope of the presentdisclosure.

In the embodiment of FIG. 8A, the core 112 includes a silica fiberhaving a diameter of approximately 440 μm that is layered with polyimidehaving a wall thickness of approximately 20 μm. The conductor layer 127can be made of aluminum at a wall thickness of approximately 600angstroms. Furthermore, the anode 114 can be made of nickel at athickness of approximately 50 angstroms. In some embodiments, the anode114 is oxidized nickel, which is oxidized using UV-ozone to lower thework function of the anode 114. The organic layer 116 can include CuPcat a thickness of approximately 30 angstroms, NPD at a thickness ofapproximately 500 angstroms, and Alq₃ at a thickness of approximately600 angstroms. Moreover, the cathode 118 can include LiF at a thicknessof approximately 10 angstroms, and aluminum at a thickness ofapproximately 150 angstroms.

As shown in FIG. 8B, the electric device 115 can be localized along thelength of the fiber-based electric apparatus 110 to define a localizedpixel 129. The pixel 129 can emit light (e.g., a green light) whenelectricity is transmitted through the conductor layer 127 and there isa voltage between the cathode 118 and anode 114/conductive layer 127.More specifically, this causes charges to be injected into the organiclayer 116 (the active layer), and light is emitted.

It will be appreciated that the pixel 129 can emit light substantiallyequally from all angles about the axis of the fiber-based electricapparatus 110 (i.e., the observation angle). FIGS. 9A-9D show emissionspectra showing the variation of light depending on the observationangle. FIG. 9A represents a planar top-emitting OLEDs on a siliconsubstrate, FIG. 9B represents a planar top-emitting OLED on polyimidesubstrate, FIG. 9C represents the fiber-based electric apparatus 110 ofFIG. 8A with variation in azimuthal angle θ, and FIG. 9D represents thefiber-based electric apparatus 110 of FIG. 8A with variation in zenithangle φ. Normal emission is taken as 90° and the inset schematicsillustrate the direction of angular variation. As shown in FIGS. 9C and9D, the spectral character of the fiber-based electric apparatus 110 issubstantially invariant to observation angle in contrast to the strongangular dependence observed in the planar devices of FIGS. 9A and 9B.

FIG. 10 illustrates current density-voltage (j-V) characteristics andexternal quantum efficiency of the fiber-based apparatus 110 (FIGS. 9C,9D) and of the planar OLEDs deposited on silicon and polyimidesubstrates (FIGS. 9A, 9B). The similar behavior between these devicessuggests comparable organic layer thicknesses. One of the fiber-basedOLED apparatuses 110 exhibits increased leakage current, attributed tosubstrate surface roughness leading to increased current shunt pathways.This suggests that a substrate “smoothing” step can be incorporated intothe manufacturing technique for producing the fiber-based apparatus 110as will be discussed.

Moreover, FIGS. 9A-10 show that the fiber-based apparatus 110 exhibitssubstantially equal current-voltage behavior to the planar OLED devicesof FIGS. 9A and 9B and have comparable quantum efficiency, while at thesame time achieving uniform emission spectrum regardless of observationangle. As such, the fiber-based apparatus 110 can be used in variousapplications, such as light-emitting (communications) composites,fabrics, etc.

Now referring to FIGS. 11 and 12, another embodiment of a fiber-basedelectric apparatus is generally indicated at 210. In this embodiment,the electric apparatus 210 is a thermoelectric (TE) device that convertsheat to electricity or converts electricity to heat (directionally) aswill be discussed.

In one embodiment, the fiber-based electric apparatus 210 includes acore 212. In one embodiment, the core 212 is a polyimide-coated silicafiber having a diameter of approximately 500 μm.

Also, as shown in FIGS. 11 and 12, the fiber-based electric apparatus210 includes an electric device 215 that is layered on and supported bythe core 212. The electric device 215 includes a first film 230 and asecond film 231. The first and second films 230, 231 are disposed inspaced relationship along the axis of the core 212. More specifically,the films 230, 231 are alternatingly disposed in strips on the core 212along the axis of the core 212. Also, in some embodiments represented inFIG. 11, the first and second films 230, 231 cover only a portion of thecore 212 and leave another portion of the core 212 exposed. Forinstance, in the embodiment of FIG. 11, the films 230, 231 coverapproximately half of the core 212 and leave the other half exposed.

In one embodiment, the first film 230 is made of silver and the secondfilm 231 is made of nickel, and each individual strip is approximately 5mm long. Also, in one embodiment, the first and second films 230, 231have a maximum thickness (r₂−r₁) of approximately 120 nm. It will beappreciated that the thickness of the films 230, 231 can vary over awide range (e.g. from nanometers to microns). In some embodiments, thethickness of the films 230, 231 has an approximately linearlyproportional effect on the power produced or dissipated by theindividual fiber-based electric apparatus 210. In selecting thethickness of the first and second films 230, 231, film continuity can beachieved, while still allowing the apparatus 210 to be relativelyflexible.

Also junctions 232 are defined where the first film 230 and second film231 abut and/or overlap. In one embodiment, the junctions 232 overlap ata length of approximately 0.5 mm.

In one embodiment of the manufacturing technique of the apparatus 210,the core 212 is masked in predetermined areas, and the first film 230 isdeposited by a well known thermal evaporation process under a vacuum of5×10⁻⁷ torr. Then, the mask is moved to substantially cover the firstfilm 230, and the second film 231 is deposited.

It will be appreciated that the embodiment of the apparatus 210represented in FIGS. 11 and 12 includes thermocouple p-n pairs with a“chain” of series-connected thermocouple junctions 232. Thus, theapparatus 210 can operate as a thermoelectric generator, in whichcross-plane heat flow generates in-plane electric current as representedschematically in FIG. 13.

Also, as represented in FIGS. 14A and 14B, the apparatus 210 can bewoven with other fibers 211 into a mat 213 for various applications. Asshown, the junctions 232 alternate between the top and bottom of the mat213 along the axial length of the apparatus 210. Thus, each junction 232produces a thermoelectric step in series voltage, and the core 212provides structural support.

It will be appreciated that the mat 213 could be configured to operateas a thermoelectric generator. It will also be appreciated that the mat213 could be configured to operate as a thermoelectric cooler, forinstance, if external power is supplied to the mat 213.

FIG. 15 is a plot of the open circuit voltage and power produced by oneembodiment of the apparatus 210 for a given temperature gradient, ΔT.FIG. 19 represents one embodiment of a power per couple versus thesegment length for different hot junction temperatures in the apparatus210. Moreover, FIG. 20 represents one embodiment of a comparison ofpower per couple from Ni—Ag thin films on a silica fiber substrate andBi₂Te₃—Sb₂Te₃ thin films on silica and polyimide fiber substrates fortemperature, T_(hot) of 100° C.

Referring now to FIGS. 16, 17, and 18, another embodiment of the mat 313is illustrated, which includes a plurality of separate fiber-basedelectric apparatuses 310, 310′. In this embodiment, the mat includes afirst fiber-based electric apparatus 310, a second fiber-based electricapparatus 310′, a plurality of conductive members 341, 341′, and aplurality insulative fibers 340, which are woven together as discussedin greater detail below.

In some embodiments, the first fiber-based electric apparatus 310includes a p-type first film 333 (a first thermoelectric component)uniformly layered and supported on its respective flexible, fiber core(not shown). Also, the second fiber-based electric apparatus 310′includes an n-type second film 335 (a second thermoelectric component)uniformly layered and supported on its respective flexible, fiber core(not shown). Additionally, in some embodiments, the insulating fiber 340is a glass fiber or insulator-coated carbon fiber that providesload-bearing functionality to the mat 313. Furthermore, the conductivemembers 341, 341′ can be made from any suitable conductive fiber orconductive ink.

When woven together into the mat 313, the apparatuses 310, 310′ arealternatingly arranged in a side-by-side manner such that the respectiveaxes of the apparatuses 310, 310′ extend in substantially the samedirection. Also, the insulating fibers 340 are each disposed betweeneach of the apparatuses 310, 310′ such that the respective axis of theinsulating fiber 340 extends in substantially the same direction as theapparatuses 310, 310′. Furthermore, one or more conductive members 341extends between and electrically connects adjacent pairs of theapparatuses 310, 310′ along a hot side 337 of the mat 313. Moreover, oneor more conductive members 341′ extends between and electricallyconnects adjacent pairs of the apparatuses 310, 310′ along a cold side339 of the mat 313. In some embodiments, the conductive members 341,341′ extend generally parallel to the axes of the apparatuses 310, 310′and generally transverse to the axes of the apparatuses 310, 310′. Itwill be appreciated that the mat 313 can also include wrap fibers (notshown).

Thus, as represented schematically in FIG. 18, the mat 313 can operateas a thermoelectric generator in which the apparatuses 310, 310′ (i.e.,the n- and p-type elements) are connected in parallel. The conductivefibers 341 heat up, and the conductive fibers 341′ cool down when poweris supplied to the apparatuses 310, 310′.

In one embodiment, the mat 213 represented in FIGS. 14A and 14B and/orthe mat 313 represented in FIGS. 16-18 can include at least one energystorage device (e.g., battery, capacitor). In one embodiment, the energystorage device is a fiber-based electric apparatus similar to theembodiments disclosed herein. The energy storage device is woven intothe mat 213, 313 and provides energy to at least one of the respectiveapparatuses, 210, 310, 310′.

Furthermore in one embodiment, the apparatuses 210, 310, 310′ include aprotective coating (not shown) on an outer surface. The protectivecoating can protect against electrical shorting, abrasion of the activelayers, and/or delamination of the active layers.

The fiber-based electric apparatuses 10, 110, 210, 310, 310′ can bemanufactured in any suitable fashion. For instance, FIG. 23A is adetailed illustration of a first machine 450 for producing one or moreof the fiber-based electric apparatuses 10, 110, 210, 310, 310′. Thefirst machine 450 includes a deposition chamber 451. The depositionchamber 451 exposes the core 12, 112, 212, 312 of the apparatus 10, 110,210, 310, 310′ to the different materials described above to create theindividual layers thereon.

FIGS. 21, 22, and 23B illustrate another manufacturing method forproduction of the fiber-based electric apparatuses 10, 110, 210, 310,310′. As shown in FIG. 21, the method generally includes unspooling thefiber core 12, 112, 212, 312, cleaning the core 12, 112, 212, 312,passive and active material deposition, encapsulation using, forinstance, the materials discussed above, and re-spooling of theapparatus 10, 110, 210, 310, 310′. The unspooling and re-spooling canadvance the fiber core 12, 112, 212, 312 as the materials are depositedthereon. As shown in FIG. 22, the materials can be deposited using avacuum thermal evaporation technique. Also, as shown in FIGS. 21 and 22,the core 12, 112, 212, 312 can be rotated about its longitudinal axisduring this process to ensure even layering of the deposited materials.

FIG. 23B illustrates a second machine 452 for manufacture of theapparatuses 10, 110, 210, 310, 310′. In the embodiment shown, the secondmachine 452 includes a plurality of stages 461-473.

In the embodiment shown in FIG. 23B, the first and thirteenth stages461, 473 have two ports dedicated to motorized spooling of the fiber andan atmosphere-vented port. Also, the second stage 462 has two portsdedicated to the jetting and collection of solvents and one port foraggressive pumping of solvent vapor. The third stage 463 is identical tothe second stage 462, but uses a dissolved polymer for planarizing thefiber. The fourth stage 464 has one port outfitted with a quartzcapillary gas inlet and a high-intensity UV lamp, and one port foraggressive pumping. The fifth through eleventh stages 465-471 each haveone port outfitted with a quartz crystal microbalance, one port forevaporation of the source material, and one port for pumping. Theevaporation source can be a temperature-controlled Radak effusion cellwith a pneumatically-actuated beam shutter. Also, the power supply forthe evaporation cell can be feedback-controlled with data from theenclosed thickness monitor. Moreover, the Radak sources can produce ahighly collimated beam that results in high deposition flux, which isimportant for rapid device deposition. In addition, the twelfth stage472 has one port with a two-zone heated capillary used for depositing aparalene-based barrier coating. The deposition occurs by firstevaporating a paralene dimer at approximately 160° C., followed by acracking at 600° C., and finally condensation/polymerization on thefiber.

In the embodiment shown, the second machine 452 is used to make a PVapparatus 10 of the type discussed above in relation to FIGS. 1A-2.However, it will be appreciated that the second machine 452 could bemodified so as to manufacture any of the apparatuses 10, 110, 210, 310,310′ discussed above. For instance, in order to manufacture theapparatuses 210, 310, 310′ discussed above, the second machine 452includes analogous stages 461-473, albeit with some of the Radak sourcesoperating at higher temperatures in order to effectively evaporateinorganic semiconductor and buffer materials.

Each stage is effectively isolated from others by virtue of localizedpumping and a highly collimated deposition beam. Coating uniformity overthe relatively large length of the fiber is achieved by means of controlover evaporation rate and steady translation of the fiber, coupled withsimultaneous rotation about the axis of the core 12, 112, 212, 312. Itwill be appreciated that the second machine 452 allows for significantreductions in manufacturing time for the apparatus 10, 110, 210, 310,310′.

It will be appreciated that the electric apparatuses 10, 110, 210, 310,310′ disclosed above can be employed for various uses. For instance,these apparatuses 10, 110, 210, 310, 310′ can be used for energyharvesting, solid state lighting, wearable displays, optical circuits,etc. Moreover, these fiber-based electric apparatuses 10, 110, 210, 310,310′ can be incorporated into vehicle bodies (e.g., flying vehicles) andother non-planar surfaces to enable the harvesting of light, heat, andvibrational energy that ordinarily affects the vehicle body. Theseapparatuses 10, 110, 210, 310, 10, 110, 210, 310, 310′ can also be usedto generate light and/or heat.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the disclosure areintended to be within the scope of the disclosure. Such variations arenot to be regarded as a departure from the spirit and scope of thedisclosure.

What is claimed is:
 1. A method of manufacturing an electric apparatuscomprising: providing a plurality of fiber-based electric apparatuses,each including an elongate flexible fiber core and at least one electricdevice layered thereon, at least one of the plurality of fiber-basedelectric apparatuses including a plurality of first films and secondfilms, the first and second films alternatingly arranged along the axisof the respective fiber core, the first films abutting correspondingones of the second films such that a plurality of junctions are definedbetween corresponding pairs of the first and second films; and operablysecuring the plurality of fiber-based electric apparatuses together intoa mat that defines a first side and a second side such that a locationof the plurality of junctions alternates in succession between the firstside and the second side along the axis of the respective fiber core. 2.The method of claim 1, wherein operably securing includes weaving theplurality of fiber-based electric apparatuses together into the mat. 3.The method of claim 1, further comprising at least one of convertingelectricity to light with the electric apparatus, converting light toelectricity with the electric apparatus, converting heat to electricitywith the electric apparatus, and converting electricity to heat with theelectric apparatus.
 4. The method of claim 3, further comprising atleast two of operating the electric apparatus as a photovoltaic device,a thermoelectric device, and a light emitting device.
 5. The method ofclaim 1, wherein operably securing includes placing at least one of thefiber-based electric apparatuses in electric communication with anotherof the fiber-based electric apparatuses.
 6. The method of claim 1,further comprising interweaving a plurality of secondary fibers with theplurality of fiber-based electric apparatuses such that the secondaryfibers each extend transverse to the axis of the respective fiber coreand such that the secondary fibers each overlay a respective one of theplurality of junctions.
 7. The method of claim 1, wherein providing aplurality of fiber-based electric apparatuses includes providing theflexible fiber core and layering the at least one electric device on thefiber core.
 8. The method of claim 7, further comprising unspooling theelongate, flexible fiber core and spooling the elongate-flexible fibercore to advance the fiber core during layering of the electric device onthe fiber core.
 9. The method of claim 7, further comprising rotatingthe elongate, flexible fiber core about an axis of the elongate,flexible fiber core while layering the electric device on the fibercore.
 10. The method of claim 7, further comprising layering the atleast one electric device via vacuum thermal evaporation.
 11. A methodof manufacturing an electric apparatus comprising: providing a pluralityof fiber-based electric apparatuses, each including an elongate,flexible fiber core and at least one electric device layered thereon,the plurality of fiber-based electric apparatuses including a firstfiber-based electric apparatus and a second fiber-based electricapparatus, the first fiber-based electric apparatus including only oneof a p-type material and an n-type material, the second fiber-basedelectric apparatus including only the other of the p-type material andthe n-type material; operably securing the plurality of fiber-basedelectric apparatuses together; and electrically connecting the first andsecond fiber-based electric apparatuses together in parallel with atleast one conductive member.
 12. The method of claim 11, whereinoperably securing the plurality of fiber-based electric apparatusestogether includes operably securing the plurality of fiber-basedelectric apparatuses together into a mat that defines a first side and asecond side, and wherein electrically connecting the first and secondfiber-based electric apparatuses together includes operativelyconnecting pairs of the first and second fiber-based electricapparatuses with a first conductive member adjacent the first side ofthe mat, and wherein electrically connecting the first and secondfiber-based electric apparatuses together includes operativelyconnecting pairs of the first and second fiber-based electricapparatuses with a second conductive member adjacent the second side ofthe mat.
 13. The method of claim 11, further comprising positioning aninsulating fiber between a pair of the first and second fiber-basedelectric apparatuses.
 14. The method of claim 11, wherein operablysecuring the plurality of fiber-based electric apparatuses togetherincludes weaving the plurality of fiber-based electric apparatusestogether.
 15. The method of claim 11, further comprising at least one ofconverting electricity to light with the electric apparatus, convertinglight to electricity with the electric apparatus, converting heat toelectricity with the electric apparatus, and converting electricity toheat with the electric apparatus.
 16. The method of claim 15, furthercomprising at least two of operating the electric apparatus as aphotovoltaic device, a thermoelectric device, and a light emittingdevice.
 17. The method of claim 11, wherein providing a plurality offiber-based electric apparatuses includes providing the flexible fibercore and layering the at least one electric device on the fiber core.18. The method of claim 17, further comprising unspooling the elongate,flexible fiber core and spooling the elongate-flexible fiber core toadvance the fiber core while layering the at least one electric deviceon the fiber core.
 19. The method of claim 17, further comprisingrotating the elongate, flexible fiber core about an axis of theelongate, flexible fiber core while layering the at least one electricdevice on the fiber core.
 20. The method of claim 17, further comprisinglayering the at least one electric device via vacuum thermalevaporation.